US20110070794A1 - Nonwoven sheet material, panel constructed therefrom and methods of construction thereof - Google Patents

Nonwoven sheet material, panel constructed therefrom and methods of construction thereof Download PDF

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Publication number
US20110070794A1
US20110070794A1 US12/822,453 US82245310A US2011070794A1 US 20110070794 A1 US20110070794 A1 US 20110070794A1 US 82245310 A US82245310 A US 82245310A US 2011070794 A1 US2011070794 A1 US 2011070794A1
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United States
Prior art keywords
sheet material
web
further including
nonwoven sheet
nonwoven
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Abandoned
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US12/822,453
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English (en)
Inventor
Harry F. Gladfelter
Christopher A. Foy
David Briggs
Eric K. Staudt
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Systems Protection Group US LLC
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Individual
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Priority to US12/822,453 priority Critical patent/US20110070794A1/en
Publication of US20110070794A1 publication Critical patent/US20110070794A1/en
Assigned to FEDERAL MOGUL POWERTRAIN, INC. reassignment FEDERAL MOGUL POWERTRAIN, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GLADFELTER, HARRY F., STAUDT, ERIC K., BRIGGS, DAVID, FOY, CHRISTOPHER A.
Assigned to CITIBANK, N.A., AS COLLATERAL TRUSTEE reassignment CITIBANK, N.A., AS COLLATERAL TRUSTEE SECURITY INTEREST Assignors: FEDERAL-MOGUL CHASSIS LLC, A DELAWARE LIMITED LIABILITY COMPANY, FEDERAL-MOGUL CORPORATION, A DELAWARE CORPORATION, FEDERAL-MOGUL IGNITION COMPANY, A DELAWARE CORPORATION, FEDERAL-MOGUL POWERTRAIN, INC., A MICHIGAN CORPORATION, FEDERAL-MOGUL PRODUCTS, INC. , A MISSORI CORPORATION, FEDERAL-MOGUL WORLD WIDE, INC., A MICHIGAN CORPORATION
Assigned to FEDERAL-MOGUL POWERTRAIN LLC. reassignment FEDERAL-MOGUL POWERTRAIN LLC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: FEDERAL-MOGUL POWERTRAIN, INC.
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4274—Rags; Fabric scraps
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/12—Vehicles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2525—Coating or impregnation functions biologically [e.g., insect repellent, antiseptic, insecticide, bactericide, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2631—Coating or impregnation provides heat or fire protection
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/654—Including a free metal or alloy constituent
    • Y10T442/656—Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the nonwoven fabric]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/682—Needled nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/696—Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/699—Including particulate material other than strand or fiber material

Definitions

  • This invention relates generally to nonwoven panels and methods for their construction, and more particularly to acoustic, thermal and/or structural panels constructed at least partially from used waste material constituents ordinarily not suitable for reprocessing, more particularly, a mixture including non-thermoplastics and/or different types of plastic/thermoplastic.
  • a nonwoven product in accordance with one aspect of the invention, includes a heat bondable textile material and a used post consumer material.
  • the used post consumer material includes at least one of a non-thermoplastic material, a thermoplastic material and a material having constituent ingredients including more than one type of plastic material.
  • the used post consumer material is bonded with the heat bondable textile material.
  • the nonwoven product is a vehicle panel.
  • the nonwoven product is a structural member.
  • the nonwoven product is constructed to be entirely biodegradable.
  • a method of constructing a nonwoven sheet material from used textile or foam disposables used in manufacturing, other production textile based waste, or other comminutable waste normally unable to be reused that is put into a landfill or incinerated because of cost, melting/bonding, or contamination issues is provided.
  • the nonwoven sheet material constructed is useful for forming at least one of structural, acoustic, thermal panels and vehicle panels.
  • the method includes providing unwashed post consumer scrap.
  • the method includes providing the post consumer scrap including at least one of a non-thermoplastic material, thermoplastic material, a plastic composition including different types of plastic constituents, and other materials containing contaminants such as dirt, oil, grease and the like in a non-washed state.
  • the method further includes comminuting the post consumer scrap into pieces of a predetermined size. Then, forming a mixture by combining the comminuted pieces with heat bondable (low melt) textile fibers, and then, forming a web of the mixture of a predetermined thickness. Further yet, forming a sheet by heating the web to bond the heat bondable material with the comminuted pieces of used waste material.
  • the method includes heating the web in an oven or via a heated roller, rollers, or series of rollers.
  • the method includes needle punching the web prior to being heated.
  • the method includes adding disposable thermoplastic material having low melt fibers to the comminuted pieces of used waste material prior to forming the web.
  • the method includes applying a reflective layer to the web.
  • the method includes treating the used waste material with at least one of an antimicrobial coating and flame retardant coating before and/or after forming the web.
  • the method includes adding a binder and heat bondable (low melt) textile fibers to the comminuted pieces of material prior to forming the web to prevent “dusting out”.
  • the method includes cooling the heated web via a cooling roller or rollers to control the loft, thickness and density of the sheet after heating the web.
  • the method includes cutting the fabricated sheet into any desired shape, depending on the application requirements.
  • the method includes adding filler fibers to the comminuted pieces of material and the low melt material to alter the finished physical properties of the finished, fabricated sheet, as desired.
  • the method includes providing a predetermined quantitative acoustic absorption property to the sheet by controlling the size and the percent by weight of the comminuted pieces of material being mixed with the heat bondable (low melt) textile fibers.
  • nonwoven panels such as those suitable for use in acoustic, thermal or structural applications and methods for their construction by recycling selected types of non-thermoplastic materials and/or materials having more than a single type of plastic constituent and using them in combination with heat bondable textile materials to create a nonwoven acoustical, thermal or otherwise structural panels that can be used in a variety of applications, such as in automobiles.
  • FIG. 1 is a perspective view of a vehicle having nonwoven panels constructed from nonwoven sheet material in accordance with one presently preferred aspect of the invention
  • FIGS. 2 and 3 are enlarged cross-sectional views of nonwoven sheet material constructed in accordance with the invention having different sizes and percents by weight of comminuted pieces of used scrap material therein;
  • FIG. 4 is a view similar to FIG. 2 shown having an outer layer of reflective material.
  • FIG. 1 illustrates a plurality of panels 10 constructed from a nonwoven sheet material 11 in accordance with one aspect of the invention.
  • the nonwoven sheet material 11 fabricated to form the panels 10 is constructed, at least in part, from unwashed post consumer, items.
  • the panels 10 can be configured for use in any number of applications, such as for an automotive vehicle component, as shown in FIG. 1 , by way of example and without limitation.
  • the panels 10 aside from being capable of providing a formable structural member, can be fabricated having noise damping or attenuation properties, thus, functioning as an acoustic panel.
  • the panels 10 can be constructed having fire retardant properties, if intended for use in high temperature environments, such as near an exhaust system or within a vehicle engine compartment, for example.
  • the panels 10 are constructed from used, reclaimed materials 12 , including at least one of non-thermoplastic materials, thermoplastic materials, plastic materials having different types of plastic constituents, other production textile based waste, and other comminutable waste, all of which are normally unable to be reused and that are ordinarily put into a landfill or incinerated because of cost, melting/bonding, or contamination issues.
  • the materials 12 are bonded within the panels 10 with heat bondable textile (low melt) fibers 14 , including single or bicomponent fibers.
  • the used waste materials 12 preferably remain in their used, unwashed state, thereby minimizing processing costs.
  • other suitable binder materials and/or filler fibers can be mixed with the used materials 12 to facilitate forming the panel 10 , depending on the end use.
  • various coatings 16 can be applied on at least one outer surface of the panel 10 prior to and/or post bonding of the materials 12 .
  • the used material 12 can be provided as a mixture including at least one of used, non-thermoplastic materials, thermoplastic material, plastic materials having different types of plastic constituents, other production textile based waste, and other comminutable waste.
  • some used products that, in accordance with the invention, can be fabricated into the sheet material 11 which, till now, were considered non-reusable “waste” include, without limitation, gloves, such as those constructed from aramid or polyester coated with silicone (more than a single polymer-based material), aprons, air filters and/or protective covers, PET tube wipes, foam robot covers, tac rags, Kevlar gloves, Kevlar sleeves, nylon gloves cotton gloves, paint sludge roll media, sweatshirts, and foam bumpers, by way of example and without limitation.
  • the heat bondable textile material can be provided, for example, as a low temperature melt polymeric material (low melt), such as fibers of polyethylene, PET or Nylon.
  • low melt polymeric materials such as thermoplastic bi-component fibers whose outer sheath, such as polypropylene, for example, melts when heated above its melting point. This melted resin then fuses and bonds with the mixture of any textile fibers present and the fibers of the used waste material 12 and with any other binders present.
  • the melting point of the outer portion of a PET low melt fiber may be between approximately 110° C.-180° C. as compared to the core melting at about 250° C.
  • the low melt material can be provided as a natural cellulosic fiber or it could also be provided from one or more of the fibers within the waste material 12 used to construct the sheet 11 .
  • Persons skilled in the art will recognize that other coatings or fillers and filler fibers may be used in place of low melt fibers to achieve the desired result, and further that the heat bondable material 14 can be used in combination with or replaced by a binder (for example, less low melt fiber can be used if a binder is used to stiffen the feel of the fabric).
  • a SBR with a Tg of +41 is one example of a binder that can be used.
  • the heat bondable textile materials 14 can be combined with other inorganic or organic fibers, such as jute or kenaf, for example, and/or coated with heat resistant or fire retardant (FR) coatings (Ammonium Sulfate, Ammonium Phosphate, or Boric Acid, for example) and/or coated with an anti-microbial coating (Polyphase 678, Rocima 200, or UF-15, for example) on at least one or both of the heat bondable textile materials and the used material 12 .
  • FR fire retardant
  • One method of constructing the panels 10 includes providing the waste materials 12 , as discussed above, such as by reclaiming used, dirty items, such as those listed above, and then, comminuting the materials 12 without being washed into the desired size pieces and/or dry fibrous state, such as in a chopping, shredding, and/or grinding operation.
  • the size and percent by weight content of the comminuted pieces or nits can be selectively varied from application to application. It has been found that by altering the size and percent content of the pieces, the acoustic absorption properties of the panels 10 changes.
  • the screen may be oriented in various directions or take on various shapes, including circular, vertical, or horizontal. If the ground/hammer-milled mixture will be combined with textile fibers, it is then fluffed to facilitate being mixed with the textile fibers.
  • Another aspect of the invention includes changing the percentage of the material 12 used in the panel 10 to customize the sound absorption curve of the final panel.
  • the material 12 may increase the sound absorption values or it may actually decrease the sound absorption values of the final panel.
  • the panel 10 can be engineered to have any absorption curve required by the application.
  • the hammer-milled fibers and fragments of the material 12 are then blended with any desired recycled or virgin textile fibers, which may include the low-melt fibers 14 , other binder materials or coatings, as mentioned.
  • the proportion of the hammer-milled fibers, if incorporated, and fragments of waste material 12 to textile fibers 14 can be varied as best suited for the intended application of the panel 10 .
  • the low melt fibers 14 can be provided in such a low percentage, such as about 5%, for example, that their content in the finished panel 10 will be substantially indiscernible.
  • the mixture is then subjected to a nonwoven webbing process, which may be performed, for example, on a Rando machine, or other more current air lay systems.
  • the webbing process forms a homogenous or substantially homogenous mixed fiber mat or web, with the fibers of the material 12 being randomly oriented.
  • the web is then run through a heat bonding oven to melt the low melt fibers.
  • the web prior to heating the web, the web can be first fed through a needle loom to be needle punched. Regardless, the heating process may be performed by passing the web into or through any suitable oven, or by feeding it through one or more heated rollers. The resulting web may then be passed between cooling rollers after heating to control its thickness and density.
  • a thin nonwoven layer that resists tearing, or a scrim layer may be applied to one or both sides of the web to prevent any of the material fibers or pieces 12 from building up on the needles, as build-up of material 12 on the needles is undesirable and may cause them to break.
  • the scrim layer also serves as a “net” to control dust from being released from the web.
  • Reemay fabric is one example of a scrim that can be used for this purpose.
  • the scrim or protective layer of fabric may additionally add strength to the web and facilitate the webbing process.
  • the web can also be coated with a binder prior and/or after heating the web, which further binds all of the fibers and material in place and prevents it from forming dust (SBR, Acrylic, or Latex binders are some examples of what can be used). Flame retardant additives can also be added to the coating.
  • a binder prior and/or after heating the web, which further binds all of the fibers and material in place and prevents it from forming dust (SBR, Acrylic, or Latex binders are some examples of what can be used).
  • Flame retardant additives can also be added to the coating.
  • Upon applying the binder it is preferably dried and cured.
  • the web can then be rolled up or cut into desired lengths.
  • a cutting press or a comparable apparatus, can be used to separate the roll/sheets into panels or parts as dictated by the application of the fiber product.
  • the resulting nonwoven panels 10 may have a thin nonwoven fabric, scrim and/or reflective layer 16 attached or bonded to one side or both sides, or sandwiched between layers of the nonwoven fiber panels 10 .
  • the scrim and/or reflective layer can be bonded using a suitable heat resistant adhesive, a low-melt blend of fibers within the scrim, or it can be attached via stitch-bonding.
  • the reflective layers 16 e.g. foil, enhance the thermal heat resistant properties of the panel 10 .
  • the panel 10 and scrim or reflective layers 16 can be structured in a lamination, thereby providing multiple layers, as desired, of panels 10 and intervening scrim and/or reflective layers 16 .
  • the nonwoven panels 10 constructed in accordance with the invention are suitable for use in a variety of applications, including acoustic panels and thermal panels in automobiles. Such applications more specifically include the acoustic panels between the finished interior panel and the steel of the car, including, the headliner, side door panels, the trunk, and under the carpet.
  • Thermal applications include, for example, heat shields with the addition of a reflective layer, such as adjacent exhaust system components or within an engine compartment. Other applications may include thermally compressed parts or composites.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
  • Cleaning Implements For Floors, Carpets, Furniture, Walls, And The Like (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
US12/822,453 2009-06-24 2010-06-24 Nonwoven sheet material, panel constructed therefrom and methods of construction thereof Abandoned US20110070794A1 (en)

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US21997209P 2009-06-24 2009-06-24
US12/822,453 US20110070794A1 (en) 2009-06-24 2010-06-24 Nonwoven sheet material, panel constructed therefrom and methods of construction thereof

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EP (1) EP2446078A4 (enExample)
JP (1) JP5603936B2 (enExample)
KR (1) KR20120106695A (enExample)
CN (1) CN102803594A (enExample)
WO (1) WO2010151627A2 (enExample)

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WO2015175761A1 (en) * 2014-05-15 2015-11-19 Zephyros, Inc. Short fiber nonwoven molded articles
US10113322B2 (en) 2014-12-08 2018-10-30 Zephyros, Inc. Vertically lapped fibrous flooring
US10460715B2 (en) 2015-01-12 2019-10-29 Zephyros, Inc. Acoustic floor underlay system
US10755686B2 (en) 2015-01-20 2020-08-25 Zephyros, Inc. Aluminized faced nonwoven materials
US11541626B2 (en) 2015-05-20 2023-01-03 Zephyros, Inc. Multi-impedance composite

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US9457739B2 (en) * 2014-11-26 2016-10-04 Federal-Mogul Powertrain, Inc. Nonwoven acoustic sleeve and method of construction thereof
CN106003352B (zh) * 2016-05-30 2018-05-25 重庆大学 一种利用废旧衣物纤维制备复合纤维板的方法
CN109403056A (zh) * 2018-11-07 2019-03-01 桐城市鸿江包装有限公司 阻燃型医用无纺布的制备方法
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US10755686B2 (en) 2015-01-20 2020-08-25 Zephyros, Inc. Aluminized faced nonwoven materials
US11541626B2 (en) 2015-05-20 2023-01-03 Zephyros, Inc. Multi-impedance composite

Also Published As

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CN102803594A (zh) 2012-11-28
EP2446078A2 (en) 2012-05-02
EP2446078A4 (en) 2013-05-15
WO2010151627A3 (en) 2011-04-28
JP5603936B2 (ja) 2014-10-08
JP2012531532A (ja) 2012-12-10
KR20120106695A (ko) 2012-09-26
WO2010151627A2 (en) 2010-12-29

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